Continuous flow hydrothermal synthesis of zeolite LTA in intensified reactor. Experimental and multiphysics CFD modeling approach

•Development of continuous flow intensified reactor for the zeolite LTA.•High quality zeolite LTA crystals were obtained in short residence time.•CFD and population balance models were coupled to closely simulate the process.•Effect of key parameters were studied by simulation of developed model.•Th...

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Bibliographic Details
Published in:Chemical engineering and processing Vol. 189; p. 109399
Main Authors: Ahmad, Sher, Mustapha, Lilia Ben, Calvo, Sébastien, Collignon, François, Fernandes, Antony E., Toye, Dominique
Format: Journal Article
Language:English
Published: Elsevier B.V 01.07.2023
Subjects:
Batch-wise
CFD modeling
Chemical engineering
Computational fluid dynamics
Continuous-flow
Crystallization
Engineering, computing & technology
Hydrothermal process
Hydrothermal synthesis
Ingénierie chimique
Ingénierie, informatique & technologie
Modeling approach
Multi-physics
Optimization
Particle size
Population balance Modeling
Population balance modelling
Process intensification
Synthesised
Zeolite LTA
Zeolites
Process intensification
Hydrothermal synthesis
Computational fluid dynamics
Zeolites
Crystallization
Population balance Modeling
ISSN:0255-2701, 1873-3204, 1873-3204
Online Access:Get full text
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Summary:•Development of continuous flow intensified reactor for the zeolite LTA.•High quality zeolite LTA crystals were obtained in short residence time.•CFD and population balance models were coupled to closely simulate the process.•Effect of key parameters were studied by simulation of developed model.•The simulations allowed to propose process optimization and scale up. Zeolites are conventionally synthesized in batch-wise hydrothermal processes that usually take several hours or days to complete. In current research work, continuous flow process is developed on pilot scale for the hydrothermal synthesis of zeolite LTA. The pilot reactor was able to produce highly crystalline zeolite nanoparticles without any clogging, which often encounters for particle flow in tubular reactors. Steady-state zeolite production rates of 55–80 g⋅h −1 (dry basis) were achieved with a residence time below 10 min, with corresponding space time yields (STY) between ca. 700 and 1100 g⋅L −1⋅h −1. A couple CFD model with a population balance model was developed to investigate the continuous flow hydrothermal process. The average particle size obtained from the model was in good agreement with the experimental data. The model was further applied to study the effects of critical parameters, such as temperature and flow rate, to highlight potential process optimization directions. [Display omitted]
Bibliography:scopus-id:2-s2.0-85154541253
ISSN:0255-2701
1873-3204
1873-3204
DOI:10.1016/j.cep.2023.109399